Stress Engineer

Overview

Expleo Group USA is seeking a Mid-to-Experienced Level Stress Engineer to support current and upcoming commercial aircraft structural engineering programs in Wichita, Kansas.

This role is ideal for an engineer with strong experience supporting Boeing aircraft programs, performing structural analysis of metallic and composite fuselage structures, and providing engineering support throughout the product lifecycle. The successful candidate will work closely with design engineering, manufacturing, suppliers, and customers to ensure safe, compliant, and efficient structural solutions.

Key Responsibilities

Structural Analysis & Substantiation

• Plan, organize, and prioritize engineering activities to meet program schedules and deliverables.
• Perform detailed stress analysis of metallic and composite aircraft structures using classical hand calculations and finite element methods.
• Support structural design changes through comprehensive analysis and substantiation.
• Evaluate structures for static strength, fatigue, and damage tolerance requirements.
• Analyze engineering changes and assess structural impacts.
• Create stress substantiation reports and supporting technical documentation.
• Develop and review structural qualification and certification plans to meet customer and regulatory requirements.
• Support production-related engineering activities and resolve structural issues affecting manufacturing and assembly operations.

Technical Coordination & Engineering Support

• Review and approve vendor drawings, stress reports, and test documentation as required.
• Coordinate with design engineers, technical leads, suppliers, manufacturing teams, and program management to ensure project objectives are achieved.
• Participate in design reviews and provide technical recommendations to improve structural performance and manufacturability.
• Present technical findings and challenge design approaches when appropriate.
• Track and communicate project status, risks, and deliverables.

Continuous Improvement

• Support engineering process improvements and best-practice initiatives.
• Ensure compliance with customer engineering methods, tools, procedures, and quality requirements.
• Demonstrate accountability, a sense of urgency, and commitment to delivering high-quality engineering solutions.

Required Qualifications

• Bachelor's Degree in Aerospace Engineering, Mechanical Engineering, Structural Engineering, or a related discipline.
• 7+ years of aerospace stress engineering experience.
• Experience supporting Boeing aircraft programs.
• Knowledge of Boeing tools, methods, processes, and engineering standards.
• Experience performing stress analysis on both metallic and composite aircraft structures.
• Strong understanding of aircraft fuselage structures and structural analysis methodologies.
• Experience with:
  • Static analysis
  • Finite element analysis (FEA)
  • Free-body diagram calculations
• Proficiency with:
  • Nastran
  • Patran
  • Abaqus
• Strong knowledge of:
  • Engineering Mechanics
  • Strength of Materials
  • Aircraft Structural Analysis
  • Structural Substantiation Processes
• Proficiency in Microsoft Excel, Word, PowerPoint, and Project.
• Excellent written, verbal, and interpersonal communication skills.
• Fuselage engineering experience required.
• Experience supporting Boeing 737 programs is highly desirable.
• Floor structure experience preferred.
• Production support engineering experience required.
• Fatigue & Damage Tolerance (F&DT) experience is a plus, but not required.
• Demonstrated technical expertise within aerospace structural analysis.

What We Offer

At Expleo, we value expertise, innovation, and collaboration. By joining our team, you'll contribute to high-impact aerospace programs while working alongside industry-leading professionals.

• Competitive Compensation – $70 - $90 per hour. Final compensation is determined based on skill alignment, years of experience, and fair, market-based rates by geography.
• Comprehensive Benefits for you and your dependents – Extensive Medical Plans, Dental, Vision, HSA with company contribution, company-sponsored Life Insurance and Short- and Long-Term Disability Insurance, a host of voluntary plans including legal, hospital, accident, pet wellness, and 401(k) with company matching.
• Paid Holidays and Paid Time Off
• Career Development and Advancement – Expleo is a global company operating in 29 countries worldwide with a strong focus on employee development and career growth.
• Strong Team Culture – Collaborate with experienced professionals who value precision, technical excellence, innovation, and teamwork. 

About Expleo

Expleo is a global engineering, technology, and consulting partner with more than 18,000 employees across over 30 countries. Since 1966, we have supported leading organizations in Aerospace, Automotive, Rail, Healthcare, Energy, and other high-tech industries, delivering engineering, production support, quality, and consulting solutions across the entire product lifecycle.

To learn more, visit www.expleogroup.com.

This position may require access to information subject to U.S. export control regulations, including ITAR and EAR requirements. Employment is contingent upon the ability to obtain such access. Under these regulations, access may be limited to U.S. Persons, including U.S. citizens, lawful permanent residents (Green Card holders), and individuals granted refugee or asylee status.

Expleo is an Equal Opportunity Employer committed to fostering an inclusive and diverse workplace. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex (including pregnancy), sexual orientation, gender identity, national origin, age, disability, genetic information, veteran status, or any other protected status under applicable law.

Benefits

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